marty24

The car is under going a major change body and Engine spec and though would post the progress so far

It started like this










The Engine and interior was removed and of it went to the body shop and has came back like this












Next job to be done was to get the front end together and get the intercooler mounted



After the bumper had been made to fit Autobahn was sprayed on





The engine has been stripped here is a few bits






Had to make the inlet manifold look more attractive so a clean an a lick of high temp paint later




The cleaned bored block ready to receive its new internals




The new set of Mahle pistons


A nice set of rods




The heads have been ported and flowed







The flywheel has been lightened and balanced with the clutch assembly



The bearings fitted into the block


Have used the ACL bearings

The crank in place


Fitting rear oil seal



The pistons fitted in the block


The heads are being held in place by ARP head bolts



Fitted one cylinder head






Then fitted the baffle and oil pick up in the bottom end followed by the sump



Then fitted the rear part to the cam belt casing followed by the cam pulleys and fitted all new idlers. Next was to time the engine up

Crank



N/S cams



O/S cams


A genuine belt has makings on it the belt is positioned with dotted line on the crank and the 2 other lines will line up with the top markings on the intake cams on both heads if they do not line up like below you have done something wrong








Which brought it to this stage



Next was to get cam belt casings on and fit the bottom pulley



Just laid the inlet manifold on to see what it looked like













Put the TD04 beside


To compare the size difference
TD04


The new Turbo


The engine is now in would of been nice to have a late one on it and get it running but we are still waiting for the parallel fuel rails and oil for the engine so will have to wait till next week now before it can be fired up

getting it into the bay







sitting nicely in there







Test fitted the down pipe



The headers and down pipe has got to be heat wrapped yet but that has not arrived as yet


Its getting there was hoping to have it running by this weekend but due to not having the parts till next week its not possible

Roll on next week

rob878

looks great, reassuring to see that i'm not the only one to take the laptop into the garage. The missus thinks it's a bit odd when i head out with hammer in one hand and laptop in the other.

slipstream_uk

iTrader: (1)

beef-on-the-bone

iTrader: (5)

looks great!!!

can't wait to see it finished

911

Great concise report!
Good luck!!
Graham

marty24

Thanks for the replys will hopefully have it running in a few days once the other bits turn up

GC8WRX

Wanna do my car next?

paulwrxboro

great project for such a small garage

mickyjeff

iTrader: (2)

yes nice thread. very good information. good luck with it and you knocked me of the top spot in projects
cheer mick lol

coulty

sorry to be negative guys but those headers look like the megan racing type that blow really easily. Better off getting a decent set before you finish the work off especially as you want to wrap them.

P20SPD

iTrader: (1)

Good work, although there are a few things that would bug me.

Why go to the trouble of respraying the whole car, and overlapping into the engine bay, and leave half the bulkhead white?

I personally think you have used way too much RTV sealant, i get criticised for using too much, but i use nowhere near that much.

The rear crank seal should really be put in once the two halves of the block have been bolted together, this i believe gives it a better chance of sealing properly.

Those headers will be a barsteward to wrap on the car, and as per the previous post, may well leak very soon.

Sorry for being negative. Good luck with finishing it.

SPEN555

Top thread and good progress report. Good luck and hope it does what you want it to in the end